Treatment of hydrocarbon gases



July 26, 1938. H. v. ATWELL I TREATMENT OF HYDROCARBON GASES Filed 001;. 5l, 1934 i Nw I--- S N ranma July 2s, 193s PATENT OFFICE i TREATMENT 0F HYDBOCARBDN GASES Harold V. Process Atwell, White Plains, N. Y., assignor to Management Company Inc., New York,

N. Y., a corporation of Delaware Application october 31, 1934, serial No. 750,857

6Claims.

My invention relates to the treatment of hydrocarbon gases and more particularly to the 'conversion of such gases to low-boiling normally liquid hydrocarbons suitable for use as motor fuel.

It is known that hydrocarbon gases containing olenic constituents such for example as ethylene,

propylene and butylene can be effectivelypolymerized by subjecting them to-elevated temperature under high pressure, with resultant formation of low boiling normally liquid hydrocarbons which are high in an anti-knock value and can be used as motor fuel. Where, however, as in the usual instance, the source of the hydrocarbon gases comprises uncondensible gases produced in the cracking of hydrocarbon oil, such polymerization under the inuence of heat and pressure tends to produce a product containing a relatively large portion of light ends.

It is also known that polymerization of such gases can be promoted even under lower temperature and pressure conditions by means of certain catalysts, prepared by combining a metallic halide with a polar compound, such as sodium chloride, and a catalyst which has been found especially suitable for this purpose comprises a sodium aluminum chloride (NaClAlCla). This catalyst has been found to be especially effective and useful for the polymerization of propylene and butylene, but has little or no eiect upon the polymerization of ethylene and owing to this fact the liquid products of polymerization in a catalytic gas polymerization operation of this character tend to be deficient in lower boiling constituents or light ends.

It is therefore an object of my invention to provide a gas polymerization process in which hydrocarbon gases containing gaseous olens may be polymerized to produce a low-boiling normally liquid product having a satisfactory balance or distribution between relatively low-boiling and relatively high-boiling constituents.

A further object of my invention is to provid an improved process for concentrating olefinic gases, such as those produced in an oil-cracking operationfprior and preparatory to the polymerization of the gases.

My invention has for further objects such additional improvements in operative advantages and results as may hereinafter be found to obtain.

My invention contemplates subjecting olenic gases, such as cracking-plant gases which have previously been subjected to fractionation to remove hydrogen and methane, to polymerization at moderately elevated temperatures and -pressures in the presence of a catalyst comprising a sodium aluminum chloride, separating liquid products of polymerization from the unpolymerized gases and subjecting these gases to further polymerization under the influence of high temperature and pressure to effect a polymerization of such constituents, as for example, ethylene, which remain unpolymerized in the initial gas polymerization step, followed by separation of the liquid products of polymerization and blending the liquid products of polymerization from both gas polymerization operations to form a balanced motor fuel.

My invention further contemplates recycling residual gases remaining after both polymerization operations, after fractionation to remove hydrogen and methane and also if desired after cracking to increase the olefinic content thereof, to the initial or catalytic gas polymerization step.

My invention further contemplates, when cracking-plant gases are used as a source of olefins for polymerization, the fractionation of the cracking-plant gases by means of a liquefied butane fraction circulated through an absorberstripper cycle, the butane solvent being supplied from the stabilizing unit of the oil-cracking unit, and residual gases from the gas-fractionating unit being scrubbed with a suitable secondary solvent from the fractionating tower of the oilcracking unit to remove butane, together with the return of the butane-enriched secondary solvent to the oil-cracking unit for recovery of the butane.

In order that my invention may be more clearly set forth and understood, I now describe, with reference to the accompanying drawing forming a part of this specification, various preferred forms and manners in which my invention may be practiced and embodied. In this drawing,

Fig. 1 is a more or less diagrammatic elevational view of apparatus for carrying out the process of my invention in a preferred embodiment, the ligure being intended to serve primarily as a, flow diagram illustrative of my process; and

Fig. 2 is a similar view of an alternative form of a portion of the apparatus illustrated in Fig. l.

Similar reference numerals designate similar parts in both of the views of the drawing.

Referring now to the figures, vapors from an oil-cracking unit which have previously been freed from heavy tarry or residual constituents enter the iractionator I from the cracking unit through a line 2. The fractionator I is provided with suitable cooling means, such as a cooling coil 3, and with conventional plates or trays 4 for assisting in the fractionation. As the vapors pass upward through the fractionator I they are partially condensed and fractionated to separate constituents heavier than gasoline, i. e., gas oil, which is removed from the fractionator I through a valved line 5. Overhead vapors from the fractionator I` pass through a vapor line Ii to a condenser l and a separator 8, gasoline condensate being removed from the separator 8 through a line 9 having a valve I0 while the gases escape from the separator 8 through a line I I.

The gases withdrawn from the separator 8 contain hydrogen, methane, higher parailins such as ethane, propane and butane and also gaseous oleflns such as ethylene, propylene and butylene,

example toia temperature in the neighborhood of 100 F., and the cooled compressed gases then enter-a. scrubber I4, which may be of conventional type, preferably internally provided with plates or trays or other gas-and-liquid contact devices I5. As the gases pass upward through the scrubber I4 they are subjected to counter-current scrubbing by mens of liqueed light hydrocarbons of the general boiling range of butane and/or pentane, and including corresponding olefins, which is introduced into the scrubber I4 through a line I 6 in sufficient amount to effect an absorption of constituents heavier than methane. The scrubbed residual gases, comprising largely hydrogen and methane, but containing also some solvent, are removed from the scrubber I5 through a line I1 having a valve I8 and passed to a secondary scrubber I9, the purpose of which is to eect the re-absorption and recovery of any solvent contained in the gases leaving the scrubber I5.

In the preferred instance shown, the gases entering the secondary scrubber I9 are washed with a heavynaphtha fraction withdrawn from a Weir 20 in the fractionator I. This fraction passes from the Weir 20 through a line 2 I having a valve 22 into the upper portion of the scrubber I9 and descends through the latter in counter-current to the rising gases, thus effecting a removal of butane and the like therefrom. Residual gases, comprising principally hydrogen and methane, are removed from the secondary scrubber I9 through a valved line 22', while the butane-enriched solvent is removed from the bottom of the scrubber I8 through a line 23 and delivered by means of a pump24 located in the line 23 to the fractionator I.

The gasoline condensate removed from the separator through the line 8 passes to a stabilizer 25 which is provided with a heating coil 26 located in the bottom thereof, cooling means such as a cooling coil 21 located in the upper portion thereof, suitable plates or trays 28 and a trap-out tray 29. In the stabilizer 25 the gasoline is subjected to re-distillation and re-fractionation to remove light constituents and gases undesired in the nal gasoline product. Overhead vapors from the stabilizer 25 pass through a line 30 and through the line II to the scrubber I5, while the stabilized gasoline is withdrawn from the bottom of the stabilizer 25 through a valved line 3|. The operation of the stabilizer 25 is so conducted and the trap-out tray 23 is so located that a fraction comprising principally butane, pentane and cor- .responding olens is withdrawn from the trapout tray 23, and this fraction passes through a line 32 wherein is located a pump 33 into the line I6 and thence through a cooler 35 into the scrubber I5, where it serves to remove gaseous constituents having heavier molecular weights than methane from the gases entering the scrubber I5, as aforesaid.

The enriched solvent reaching the bottom of the scrubber I5 is withdrawn through a line 35 having a valve 31 and passes to a stripper 38, which is internally provided with plates or trays A39 and with heating means such as heating coil 40 located in the bottom thereof. In the stripper 38 the enriched butane solvent is re-distilled and re-fractionated to drive off absorbed vapors and gases, the liberated vapors and gases passing through a line 4I to a condenser 42 anda separator 43 from which a portion of the condensate is returned through a valved line 44 and a pump 45 tothe upperl portion of the stripper 38. The stripped butane fraction reaching the bottom of the stripper 38 passes by way of a line 46, wherein is located a. pump `41, either-through a'branch-line 48 having a valve 49 to the line I6 and thence into the scrubber I5, or through a branched conduit n50 having a valve 5I into the upper portion of the stabilizer 25. By regulating the valves 49 and 5I the proportions of the butane returned to the scrubber I4 and stabilizer 25 respectively may be varied as desired. For example, all of this stripped fraction may be returned to the stabilizer 25.

The gases removed from the separator 43, which have been concentrated in olenlc constituents by reason of theY removal of hydrogen and methane therefrom, pass by way of a line 52 having a valve 53 and a pump 54 into a heating coil 55 located in a furnace 56; Additional oleilnic gases from an outside source (not shown) may also *bel introduced into the line -52 for delivery to the Ycoil 55 by means of a line 51 having a valve 58. A portion of the condensate withdrawn from the separator 43 may also be delivered, by way of a valved line 44', to the line 52 and thence to the coil 55, where it will be vaporized before passing to the reaction chamber 60.

The gases passing through the coil 55 are preferablyl heated to a temperature of from.300 to 400 F., under a pressure of from 500 to 1000 pounds per square inch, and atthis temperature and under this pressure pass through a line 5I into a reaction zone or chamber 60 containing a supply of catalyst.

As catalysts for this purpose I prefer to employ metallic halides which have been treated to form complexemolecular compounds by'means of polar compounds. Thus, a metallic Ahalide such as aluminum chloride may be treated with a halide of an alkali metal-such as sodium chloride, to form sodium laluminum chloride (NaClAlCla). Other metallic halides, such as ferrie chloride and boric trifluoride, and other polar compounds such as potassium chloride, sodium bromide or postassium bromide may be used. The preferred sodium aluminum chloride catalyst may be prepared Yby fusing equi-molecular proportions of anhydrous sodium chloride and aluminum chloride and is preferably suspended for use on 'an inert carrier such as pumicenor other granular material, preferably from to 20 mesh per inch in size. It w-illbe understood.that while I have shown the catalyst as located in a reaction chamber 60 of more or less conventional type, contact between theecatalyst and the gases may 'be obtained in any convenient manner and by means of any convenient apparatus which may be cooled if desired to remove excess heat of reaction. Preferably the time of contact between the gases and the catalyst is of the order of 100 seconds but may vary from about 50 to 200 seconds, as desired.

The products then pass from the reaction chamber 60 through a line 6I to a fractionator 75 02. from which products heavier than ga/soline are withdrawn through a valved line i2', and thence through a line 03 to a condenser 64 and a separator 55, from which unpolymerized gases are withdrawn through a line 68 having a valve 61. Liquid products of polymerization are withdrawn from the separator 05 through a line 68 having a valve 69. and pass to a conventional stabilizer 10, from which overhead gases return by way of a line .12 to the line 66 while stabilized motor fuel products pass through a valved line 13 into a receiver 14.

The olefinic gases passing through the line 68 which may ii desired be supplemented with additional oleiinic gas from an outside source through a valved line 65 are compressed by means of a pump or compressor 15 to a high pressure, for example from 1,000 to 3,000 pounds or higher, and are then passed into a coil 18 located in a furnace 11, where they are heated, to a polymerizing temperature of, for example from 850 to 1200 F.,-and preferably from 1000 to 1100" F., to initiate or eect polymerization oi' gaseous olefns. The products from the coil 15 may then. pass either directly through a line 18 to a condenser 10, or may rst pass through a reaction vessel 80. In any event, the time of contact is of the same order of magnitude as that employed in the catalytic gas-polymerization unit. From the condenser 19 the gases and condensate pass to a high-pressure separator 8|, where hydrogen and methane may be separated and removed through a valved line 82 while condensate passes throughl a line 83 having a pressure-reducing valve 84 into a low-pressure separator 85, which may be constructed as a conventional stabilizer if desired.

Gases Withdrawn from-the low-pressure separator or stabilizer 85, and comparatively richin olenic constituents or parainic constituents heavier than methane as compared to the gases withdrawn at 82, pass by way of a line 86 having a valve 81 and a pump 88 to the line and thence into the scrubber I4. Condensate may pass through a valved line 90 to a receiver 9|. or, where insuicient stabilization has been effected at 85, may be delivered by means of a line |20 having a valve |2| and a pump |22 to the stabilizer 25.

When it is desired to increase the-olefinic constituents of the gases withdrawn from theseparator 85, a valve 92 located in the line 86 may, be closed and the gases from the separator 85 may pass through a line 93 having a valve 94 into a coil 95 located within a gas-cracking furnace 96. The gases passing through the coil 95 are heated to a gas-cracking temperature of for example from 1250 lto 1750" F. under a comparatively low pressure of from atmospheric to 200 pounds per square inch and for a compara'- tively short period of time, for-example from one or two seconds to 20 seconds in order to effect a conversion of gaseous paraiims to gaseous loleilns. The cracked gases then pass by way of a line |31r having a valve 98 into a drum 99. Oil or oleflnic 1 gases may be introduced through the transfer line 91 by means of a line |00 having a pump |0| and a valve |02 for the purpose of quenching the hot gases. Oil, thus introduced in proper quantity, may be utilized as a source of further oleilnic gases, which are produced by the cracking of the oil introduced into chamber 99 under the iniluence of the hot gases.

Residual liquid products which may be formed during the cracking oi' the gases in the coil 85 or may comprise residual constituents of oil introduced through the line are withdrawn from the drum 99 through a valved line |03 for disposition as desired, while gaseous and vaporous products pass through a line |04 to a condenser and then to a separator |00 where any light condensate may be separated and withdrawn through a line |01. 'More elaborate fractionating means may of course be provided, especially where oil is introduced at |00. The cracked gases issuing from the separator |00 pass through a line |08 having a pump |00 and a valve ||0 into the line 88 and are delivered into the scrubber |4 for concentration.

As will be made clear from the discussion hereinabove, the products collected in the receiver 14 tend to be deficient in light constituents, while those collected in the receiver 8| tend to contain an excess of light constituents. 'Ihe productsfcollected in these receivers are therefore blended by delivering them in the quantities in which they are produced or in any other desired proportion into a blending tank l valved lines ||2 and ||3 being provided for this purpose. The blended motor-fuel product may then be withdrawn from the blending tank through a valved pipe ||4 for use as desired or for further puriiication. If desired this product may be blended with stabilized gasoline drawn from the stabilizer 25 of the oil-cracking unit from which the gases supplied to the operation are derived.

If desired, a single gas separator may be employed in place of the highand low-pressure separators 8| and 85. 'Ihe gases from such a separator may pass either directly to the scrubber I5, or may rst pass to the coil 95 for cracking, or may be withdrawn from the system. When two separators 8| and 85 are used, the gases from the separator 8| may, -if they contain enough paraiiinic constituents heavier than methane to warrant it, be delivered to the coil 95 for cracking to increase the olenic content thereof, the cracked gases returning to the scrubber i4.

In some instances, it may be desirable to employ the reaction vessel 60 as a gas reversion zone. As shown in Fig. 2, oil, such as reduced crude or other heavy hydrocarbon oil may then be introduced under pressure into the vessel 60 from an outside source through a line |30 having a pump |3| and a valve |32, to undergo cracking and/or reaction with gases in the presence of the catalyst, under the conditions of pressure and temperature set forth hereinabove.

In this instance, the line 6| may be provided with a pressure-reducing valve |33 and the products from the vessel 60 pass into an evaporator |34, from which residual products are removed through a valved line |35, while vapors pass through a trap-out 'tray |35 into the fractionator 62.

The condensate withdrawn at 62' may be separately cracked to produce gasoline for blending with other products in the tank While I have described my invention with respect to various speciiic examples and modiiications by way of illustrative examples and have illustrated various preferred forms of. apparatus for carrying out the various operations incident to my process, it will be understood by those skilled in the art that my invention is not limited to such operative or mechanical details except insofar as set forth in the claims hereinafter made.

I claim:

heavier than gasoline, condensing the fraction-A;Av ated vapors, separating uncondensed gases fromy 1. A process oi.' producing motor fael from cracked hydrocarbon vapors which comprises fractionating said vapors to remove constituents heavier than gasoline, condensing the fractlon= ated vapors, separating` uncondensed gases from vcondensed cracked distillate, passing said condensed distillate to a stabilizing zone. withdrawing from said stabilizing zone a liquid fraction comprising principally butane, scrubbing said uncondensed gases with said butane fraction to remove constituents of higher molecuiar'weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive oif constituents absorbed from said gases, subjecting the thereby liberated gaseous constituents to polymerization to eect the formation of low-boiling normally liquid hydrocarbons, and recovering said hydrocarbons from the remaining unpoiymerized gases.

2. A process of producing motor fuel from cracked hydrocarbon vapors which comprises fractionating said vapors to remove constituents condensed cracked distillate, passing said con'- densed distillate to a stabilizing zone, withdraw 1 ing from said stabilizing zone a liquid fraction comprising principally butane, scrubbing said uncondensed gases with said butane fraction to remove constituents of higher molecular weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive off constituents absorbed from said gases, 7"

subjecting the thereby liberated gaseous constituents to polymerization to effect the forma,-

recovering said hydrocarbons from the remainingy unpolymerized gases, withdrawing residual gases from the scrubbing operation, scrubbing them with a solvent heavier than butane to remove butane therefrom, returning thereby recovered butane to the vapors undergoing fractionation.

3. A process of producing motor fuel from cracked hydrocarbon vapors which comprises fractionating said vapors to remove constituents heavier than gasoline, condensing the fractionated vapore, separating uncondensed gases from condensed cracked distillate, passing said condensed distillate to a stabilizing zone, withdrawing from said stabilizing zone a liquid fraction comprising principally butane, scrubbing said uncondensed gases with said butane fraction to remove constituents of higher molecular weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive` off constituents absorbedkfrom said gases, subjecting the thereby liberated gaseous constituents to polymerization to eil'ect the formation of low-boiling normally liquid hydrocarcracked hydrocarbon vapors which comprises bons, recovering said hydrocarbons from the remaining unpolymerized gases, scrubbing residbutane-enriched solvent to said fractionatingl step.

4. A process of producing motor fuei from fractionatig said vapors to remove constituents heavier than gasoline, condensing the fractionated vapors, separating uncondensed gases from `condensed cracked distillate, Apassing said condensed distillate to a stabilizing zone, withdrawing from said stabiiizing zone a light overhead vaporous fraction and a heavier liquid fraction comprising principally butane, scrubbing said uncondensed gases and said vaporous .fraction with said butane fraction to remove constituents of higher molecular weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive oi! constituents absorbed from said gases, subjecting the condensed cracked distillate, passing said condensed distillate to a stabilizing zone, withdrawing from said stabilizing zone a light overhead with said butane fraction to remove constituents of higher molecular weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive oif'constituents vabsorbed from said gases, subjecting the thereby liberated gaseous constituents to polymerization to effect the formationbf lowboiling normally liquid hydrocarbons, and recovering said hydrocarbons from the remaining unpolymerized gases and returning' at least a portion of saidremaining gases to the scrubbing operation.

6. A process of producing motor fuel from cracked hydrocarbon vapors which comprises fractionating said vapors to remove constituents heavier than gasoline, condensing the fractionated vapors, separating uncondensed gasesv from condensed cracked distillatepassing said condensed distillate to a stabilizing zone, withdrawing from said stabilizing zone a liquid fraction comprising principally butane, scrubbing said uncondensed gases wlth said butane fraction to remove constituents of higher molecular weight than methane, removing the thereby enriched butane fraction from said gases and distilling it to drive off constituents absorbed from said gases, subjecting the thereby liberated gaseous constituents to polymerization in the presence of a catalyst comprising a metallic 'halide combined with a polar compound at an elevated temperature and high pressure to effect the formation of low-boiling, normallg.Y liquid hydrocarbon oil Icontaining motor fuel deficient in lower boiling constituents, recovering said oil, subjecting residual gases to a higher temperature and pressure to effect a further polymerization of gaseous oleiins to normally liquid, low-boiling hydro- .,carbon oil containing motor fuel deficient in higher boiling constituents, recovering said oil 'f and blending it with the first-mentioned low- I boiling hydrocarbon oil to produce a motor fuel product, and returning residual gases to the scrubbing step.

HAROLD V. ATWELL. 

